OEM 2002 Chevrolet Impala Intake Manifold

2002 Chevrolet Impala Parts Questions & Experts Answers

• Q: How to replace the upper intake manifold on 2002 Chevrolet Impala?

  A: Begin by disconnecting the negative Battery Cable for upper Intake Manifold replacement. The repairs start with disconnecting the vacuum hoses that lead to both the Fuel Pressure Regulator and evap canister purge valve and manifold vacuum source and Brake Booster and heater and air conditioning source. Workers should disconnect electrical connectors from the following components on the upper Intake Manifold: exhaust gas recirculation (EGR) valve and mass air flow (MAP) sensor, intake air temperature (IAT) sensor, idle air control (IAC) valve, throttle position (T/P) sensor and evap canister purge valve. First drain the cooling system then disconnect the air cleaner intake duct. Protect the Throttle Body by detaching its cables with bracket that control the accelerator and cruise functions. Also detach the left side Spark Plug wire harnesses from their spark plugs. The service requires removal of the cmp sensor wiring harness along with left side Spark Plug wire harness and engine wiring harness from their hold-down points. Throttle body technicians must disconnect Throttle Body bypass pipe coolant hoses (3,4) before proceeding to extract the Ignition Coil bracket with its attached coils, evap canister purge valve, manifold absolute pressure (MAP) sensor plus its bracket and the EGR Valve. Remove the right upper Intake Manifold bolts and studs before taking out the left upper Intake Manifold bolts until the upper Intake Manifold and gasket can be removed. When replacing the upper Intake Manifold you must also remove the Throttle Body because it requires cleaning the upper intake gasket seating surfaces. Installation procedures start with the Throttle Body first followed by upper Intake Manifold gasket installation and upper Intake Manifold installation. Start by torquing the left upper Intake Manifold bolts to 25 nm (18 ft. Lbs.) just before securing the right upper Intake Manifold bolts and studs. First reinstall the EGR Valve and the MAP Sensor bracket along with sensor and the evap canister purge valve. Traffic the Ignition Coil bracket and coils into position before connecting the thermostat bypass pipe coolant hoses (3,4) to the Throttle Body. The harnesses for the engine wiring and both left side Spark Plug Wires and cmp sensor wiring should be installed in their retaining locations before wiring the left side Spark Plug leads to their desired plugs. You must reconnect all Throttle Body components by joining the cruise control cables to the accelerator control bracket before installing the air cleaner intake duct. Attach electrical wiring to the evap canister purge valve and to the t/p sensor, iac valve and iat sensor and maf sensor and EGR Valve. After reattaching the negative Battery Cable and filling the cooling system, install the vacuum hoses to the heater and air conditioning source, Brake Booster, manifold vacuum source, evap canister purge valve, and Fuel Pressure Regulator.